Stacked package structure and method for manufacturing the same
Technical Field
The present invention relates to a semiconductor package, and more particularly, to a stacked package and a method for fabricating the same.
Background
The technology of stacking multiple chips has been applied to different semiconductor package structures to achieve miniaturization of integrated circuit devices, and the prior art uses wire bonding or Through Silicon Vias (TSVs) in combination with micro bumps to form electrical connections between the stacked chips and external terminals, however, the prior art has drawbacks.
When the chip is connected to the external terminal by wire bonding, gaps must be reserved between the bonding wires to prevent the adjacent bonding wires from contacting each other, and these gaps inevitably increase the volume of the stacked package structure of the prior art, so that the stacked package structure with the bonding wires of the prior art is not easy to achieve miniaturization. In addition, the wire bonding process takes much time because all bonding wires cannot be formed at the same time, and thus the yield per hour (UPH) of the stacked package structure manufactured by the wire bonding process is relatively low.
When the wafers are connected to each other by the TSVs and the micro bumps, the TSVs increase the stacking height and the complexity of the process, so that the thickness of the package structure is increased and the process yield is reduced. In addition, the requirement for alignment and positioning accuracy between the micro bumps is high, and when the size of the stacked package structure in the prior art is increased, the position deviation of the micro bumps is increased, which finally results in poor process yield.
Disclosure of Invention
Accordingly, the present invention is directed to improving the problems of low reliability and low UPH in the prior art.
To achieve the above object, the present invention adopts a technical means to create a stacked package structure, which comprises:
a plurality of chip package structures stacked on each other, each chip package structure comprising:
two side edges;
a chip having an active surface and a back surface opposite to the active surface;
a passivation layer disposed on the active surface of the wafer; and
multiple outer conductive elements arranged on the active surface of the wafer and electrically connected with the wafer, each outer conductive element having a cutting edge exposed out of at least one of the wafer packaging structures
On the side edge;
a plurality of adhesive layers respectively arranged between the adjacent wafer packaging structures;
a first packaging material, which wraps the chip packaging structure and is provided with a through hole arranged along the cutting end edge, wherein the through hole is formed in the first packaging material;
a side wire, which is arranged in the through hole of the first packaging material and is electrically connected with the cutting end edge of the wafer packaging structure;
a base, which is arranged on the bottom surface of the bottommost wafer packaging structure and the bottom surface of the first packaging material in the mutually stacked wafer packaging structures and is provided with an internal connection structure, and the internal connection structure is electrically connected with the side lead;
a third packaging material covering the side wire; and
and a metal layer arranged on the third packaging material and electrically connected with the base.
Another technical means adopted by the present invention is a method for manufacturing a package-on-package structure, comprising the steps of:
providing a plurality of chip package structures, wherein each chip package structure comprises:
a chip having an active surface and a back surface opposite to the active surface;
a passivation layer disposed on the active surface of the wafer; and
a plurality of outer conductive elements which are arranged on the active surface of the wafer and electrically connected with the wafer, and are provided with a cutting end edge which is exposed out of at least one side edge of the wafer packaging structure;
providing a substrate, wherein the substrate comprises:
an internal circuit; and
a plurality of upper connection pads electrically connected to the internal circuit and the side wires;
stacking the wafer packaging structures on the substrate, wherein the back surfaces of the wafer packaging structures face the active surface of the wafer packaging structure adjacent to the wafer packaging structures, the plurality of adhesion layers are respectively arranged between the adjacent wafer packaging structures, and the substrate is arranged on the bottom surface of the wafer packaging structure at the bottommost part in the mutually stacked wafer packaging structures;
arranging a first packaging material to cover the chip packaging structure on the substrate;
arranging a through hole on the first packaging material to expose the cutting end edge, wherein the through hole is formed in the first packaging material;
arranging a side wire in the through hole to form electric connection with the cutting end edge and the upper connecting pad;
performing singulation to form a plurality of stacked package structures.
Another technical means adopted by the present invention is a method for manufacturing a package-on-package structure, comprising the steps of:
providing a plurality of chip package structures, wherein each chip package structure comprises:
a chip having an active surface and a back surface opposite to the active surface;
a passivation layer disposed on the active surface of the wafer; and
a plurality of outer conductive elements which are arranged on the active surface of the wafer and electrically connected with the wafer, and are provided with a cutting end edge which is exposed out of at least one side edge of the wafer packaging structure;
stacking the wafer packaging structures on a carrier plate, wherein the back surfaces of the wafer packaging structures face the active surface of the wafer packaging structure adjacent to the wafer packaging structures, a plurality of adhesion layers are respectively arranged between the adjacent wafer packaging structures, and the carrier plate is arranged on the bottom surface of the wafer packaging structure at the bottommost part in the mutually stacked wafer packaging structures;
arranging a first packaging material to cover the chip packaging structure on the carrier plate;
arranging a through hole on the first packaging material to expose the cutting end edge, wherein the through hole is formed in the first packaging material;
arranging a side wire in the through hole to form electric connection with the cutting end edge;
removing the carrier plate to expose the side wires;
arranging a rewiring layer to be electrically connected with the end part of the side lead;
performing singulation to form a plurality of stacked package structures.
The invention has the advantages that the side lead is arranged in the through hole of the packaging material and is electrically connected with the cutting end edge of the chip packaging structure, and the inner connecting structure is arranged in the base to electrically connect the side lead with the external terminal, thereby simplifying the manufacturing method for forming the electrical connection, and providing the whole reliability of the stacked packaging structure and the UPH for manufacturing the stacked packaging structure.
Drawings
Fig. 1A is a top sectional view of a first embodiment of a chip package structure of a package on package structure according to the present invention.
FIG. 1B is a front sectional view of the chip package structure shown in FIG. 1A.
FIG. 1C is a cross-sectional side view of the chip package structure of FIG. 1A.
Fig. 2A is a top sectional view of a second embodiment of a chip package structure of a package on package structure according to the present invention.
Fig. 2B is a front sectional view of the chip package structure of fig. 2A.
Fig. 2C is a cross-sectional side view of the chip package structure of fig. 2A.
Fig. 3A is a top sectional view of a third embodiment of a chip package structure of a package on package structure according to the present invention.
FIG. 3B is a front cross-sectional view of the chip package structure of FIG. 3A.
FIG. 3C is a cross-sectional side view of the chip package structure of FIG. 3A.
FIGS. 4, 6A, 7A, 8A, 9A, 10 and 11 are front sectional views of the package-on-package structure in the manufacturing process according to the first embodiment of the manufacturing method of the present invention.
FIGS. 5A, 5B, 7B, 8B and 9B are top views of the package-on-package structure in process according to the first embodiment of the method of manufacturing of the present invention.
Figure 12A is a front cross-sectional view of a first embodiment of a package on package structure of the present invention.
Figure 12B is a front cross-sectional view of a second embodiment of a package on package structure of the present invention.
Fig. 13 to 15 are front sectional views of stacked package structures in processes according to a second embodiment of the manufacturing method of the present invention.
FIG. 16 is a front cross-sectional view of a stacked package structure in various processes according to a third embodiment of the stacked package structure of the present invention.
FIG. 17 is a front cross-sectional view of a stacked package structure in process steps of a fourth embodiment of the stacked package structure of the present invention.
FIGS. 18A, 19A, 20 and 21 are front sectional views of a stacked package structure in process according to a fourth embodiment of the method of fabricating the present invention.
FIGS. 18B and 19B are top views of a stacked package structure in process according to a fourth embodiment of the method of manufacturing of the present invention.
FIG. 22 is a front cross-sectional view of a stacked package structure in process according to a fifth embodiment of the manufacturing method of the present invention.
Wherein, the reference numbers:
10. 10A, 10B chip package structure 11, 11A, 11B chip
111. 111A, 111B active surface 112 back surface
12. 12A, 12B passivation layer 13 outer conductive element
130 cutting edge 131 pad
132 external lead 133A conductive pad
134B bond pad 135B through silicon via
100 chip stack 20 adhesion layer
30 first packaging material 40 chip package
50 substrate 51 internal circuit
52 upper connecting pad, 53 lower connecting pad
50B Carrier 51B dielectric layer
52B circuit layer 60 second encapsulant
61 perforation 62 cut the street opening
63C EMI opening 70 side conductor
71 thin metal layer 72 photoresist layer
80. 80C third packaging material 81 external terminal
82. 82C metal layer 83C conductive line
90. Semi-finished product of 90C stacked package structure and 900B stacked package structure
901B back side
Detailed Description
The present invention will be further described with reference to the drawings and the embodiments thereof, wherein the drawings are simplified for illustrative purposes only, and the structures and methods of the present invention will be described by describing the relationship between elements and components thereof, so that the elements shown in the drawings are not necessarily in actual number, actual shape, actual size, and actual proportions, or the dimensions and proportions thereof have been exaggerated or simplified to provide a better illustration, and the actual number, actual shape, or actual proportions of the elements may be selectively designed and arranged, and the detailed layout of the elements may be more complicated.
Referring to fig. 12A, a stacked package structure 90 of the present invention includes a plurality of chip package structures 10, each chip package structure 10 includes a plurality of sides, a chip 11, a passivation layer (passivation layer)12 and a plurality of outer conductive elements 13. The chip 11 has an active surface 111 and a back surface 112, the back surface 112 and the active surface 111 are located on opposite surfaces, the passivation layer 12 is disposed on the active surface 111, the outer conductive elements 13 are disposed on the active surface 111, each outer conductive element 13 has a cut edge (cut edge)130, and the cut edge 130 is exposed at least one side of the chip package structure 10. In one embodiment, the cutting edge 130 of the outer conductive element 13 is exposed at a plurality of sides of the chip package structure 10. Various embodiments of the chip package structure 10 are shown below, but the invention is not limited thereto.
As shown in fig. 1A to 1C, the chip package structure 10 includes a plurality of bonding pads 131, a plurality of external wires 132, and a chip dielectric layer 14, each bonding pad 131 is disposed on the active surface 111 and is covered by the passivation layer 12, each external wire 132 is disposed on the corresponding bonding pad 131 and extends out of the passivation layer 12, each external wire 132 has an end portion exposed on one side of the chip package structure 10, and the chip dielectric layer 14 is disposed on the passivation layer 12 and the external wires 132 and may be a polyimide (polyimide) layer.
As shown in fig. 2A to 2C, the chip package structure 10A includes a plurality of conductive pads 133A, each conductive pad 133A is disposed on the active surface 111A of the chip 11A and is covered by the passivation layer 12, and each conductive pad 133A has an end exposed on one side of the chip package structure 10A.
As shown in fig. 3A to 3C, the chip package structure 10B includes a plurality of bonding pads 134B and a plurality of Through Silicon Vias (TSVs) 135B, each bonding pad 134B is disposed on the active surface 111B of the chip 11B and is covered by the passivation layer 12B, each through silicon via 135B is disposed in the chip 11B and coupled to the corresponding bonding pad 134B, and each through silicon via 135B has an end exposed on one side of the chip package structure 10B.
In summary, the cutting edge 130 of each outer conductive element 13 can be an external wire 132 as shown in fig. 1A to 1B, a conductive pad 133A as shown in fig. 2A to 2C, or a through silicon via 135B as shown in fig. 3A to 3C. The ends of the external wires 132 shown in fig. 1A to 1B, the conductive pads 133A shown in fig. 2A to 2C, and the through-silicon vias 135B shown in fig. 3A to 3C may be exposed at least one side of the chip package structures 10, 10A, 10B.
Fig. 4 to 11 show a manufacturing method of the present invention, which comprises the following steps:
referring to fig. 4, a plurality of chip packages 10 are stacked to form a chip stack 100, a plurality of adhesive layers 20 are disposed between adjacent chip packages 10 to adhere the chip packages 10 to each other, the adhesive layers 20 are disposed on a back surface 112 of the chip 11, and the adhesive layers 20 may be Die Attach Film (DAF), epoxy resin (epoxy), insulating paste (insulating paste) or the like. The chip package structures 10 may be aligned with each other by a fine alignment process, or may be misaligned without performing an alignment process.
Referring to fig. 5A and 5B, a plurality of chip stacks 100 are encapsulated by a first encapsulant (encapsulating) 30, and diced by the first encapsulantThe package material 30 encapsulates the die stack 100 to form at least one die package 40, and the first package material 30 can provide package protection for the die stack 100 to prevent short circuit or contamination and provide structural stability during the dicing process. In one embodiment, after the die stack 100 is diced, the dicing edges 130 of at least one side of the die package structure 10 are exposed and aligned with each other. In one embodiment, when the die packages 10 are not aligned with each other to form the die stack 100, the die stack 100 is cut such that the die packages 10 are aligned with each other, as shown in fig. 4, which is an offset D between the die packages 101And may be less than half the pitch (pitch) of the conductive elements 13 to avoid defects when the stack 100 is diced.
Referring to fig. 6A, the chip package 40 is arranged on a substrate 50, the chip package 40 is covered by a second encapsulant 60, the chip package 40 can be attached to the substrate 50, and the carrier 50 includes an internal circuit 51, a plurality of upper connecting pads 52, and a plurality of lower connecting pads 53. The upper bonding pads 52 and the lower bonding pads 53 are formed on opposite sides of the substrate 50 and electrically connected to the internal circuit 51, the chip package 40 is disposed on the upper bonding pads 52, and the second encapsulant 60 can protect the chip stack 100 from short circuit or contamination.
Referring to fig. 7A and 7B, a through hole 61 may be formed on the second encapsulant 60 to expose the cut edge 130 at least one side. In one embodiment, the second encapsulant 60 is partially removed to form a through hole 61, the through hole 61 is disposed at a side of the cutting edge 130, and one of the upper connection pads 52 of the substrate 50 is exposed. In one embodiment, a plurality of through holes 61 are formed in the second encapsulant 60, wherein the through holes 61 are respectively disposed at the side edges of the cutting edge 130 and expose the upper connection pads 52 of the substrate 50. In one embodiment, the through hole 61 is formed by removing the second encapsulant 60 using an etching process that also ensures that the cut edges 130 are coplanar when exposed. In one embodiment, the second encapsulant 60 is partially removed to form at least one scribe line opening 62, wherein the scribe line opening 62 is disposed around the chip package 40.
Referring to fig. 8A to 9B, a side wire 70 is disposed in the through hole 61 and electrically connected to the cutting edge 130. In one embodiment, a plurality of side wires 70 are respectively disposed in the through holes 61, and the side wires 70 can be formed by sputtering (sputtering), electroplating (electroplating), or the like. In another embodiment, a thin metal layer 71 is formed on the walls of the through hole 61 and the scribe line opening 62, a photoresist layer 72 is covered on the scribe line opening 62, the side wire 70 is formed in the through hole 61 (as shown in fig. 8A and 8B), the thin metal layer 71 and the side wire 70 can be formed by sputtering (sputtering), electroplating (electroplating), etc., and then an etching process is performed to remove the thin metal layer 71 in the scribe line opening 62 after removing the photoresist layer 72, so that only the top thin layer of the side wire 70 is removed together with the thin metal layer 71 in the etching process because the side wire 70 is disposed in the through hole 61 to form a thicker metal wire.
Referring to fig. 10, the second encapsulant 60, the chip package 40 and the side wires 70 are covered by a third encapsulant 80. In one embodiment, the scribe line openings 62 are also filled with the third encapsulant 80.
Referring to fig. 11, a plurality of external terminals 81 are respectively disposed on the lower connection pads 53 of the substrate 50, and the external terminals 81 may be a plurality of solder balls (solder balls), a plurality of solder pastes (solder paste), a plurality of connection pads, or a plurality of connection pins. The chip package 40 is singulated along the scribe line openings 62 to form a plurality of stacked package structures 90.
By the cutting edge 130 exposed on at least one side of the chip package structure 10, the electrical connection between the chips 11 can be achieved through the side wires 70 disposed in the through holes 61 and the cutting edge 130 on the side, and the electrical connection between the chips 11 and the external terminals 81 can also be achieved through the substrate 50, the side wires 70 disposed in the through holes 61, and the cutting edge 130 on the side, so that the present invention simplifies the manufacturing method for forming the electrical connection, thereby improving the reliability of the stacked package structure 90 and the UPH of manufacturing the stacked package structure 90. Furthermore, since the chip package structure 10 can be aligned after the dicing process shown in fig. 5A and 5B and the dicing edges 130 can be coplanar after the etching process shown in fig. 7A and 7B, the required precision in stacking the chip package structures 10 can also be relatively low, and thus, the manufacturing method of the present invention is further simplified to improve the UPH for manufacturing the stacked package structure 90.
In one embodiment as shown in fig. 12A, the stacked chip package structure 90 includes a plurality of stacked chips 11 covered by a third encapsulant 80 and a second encapsulant 60, and the stacked chips 11 can be electrically connected to an external circuit board through a cutting edge 130, a side wire 70, an internal circuit 51 of the substrate 50, and an external terminal 81.
In one embodiment of the stacked chip package structure 90A shown in fig. 12B, the third package material 80 is covered by a metal layer 82, the metal layer 82 is grounded or electrically connected to a voltage source to provide an electromagnetic interference shield (EMI shield), and the metal layer 82 can be formed by sputtering.
The method for manufacturing a package on package structure according to another embodiment of the present invention includes, but is not limited to:
referring to fig. 13, the chip package 40 is disposed on a carrier 50B and covered by the second packaging material 60, then the second packaging material 60 is partially removed to expose the side cut edge 130 and form a through hole 61, and then the side wire 70 is disposed in the through hole 61. In one embodiment, the steps of partially removing the second encapsulant 60 and forming the side wires 70 are the same as those shown in fig. 7A-9B.
Referring to fig. 14, the second packaging material 60, the chip package 40 and the side wires 70 are covered by the third packaging material 80 to form a stacked package structure semi-finished product 900B. In one embodiment, the third encapsulant 80 is formed in the same manner as shown in fig. 10. The carrier 50B is then removed to expose the back side 901B of the stacked package structure semi-finished product 900B. In one embodiment, the carrier 50B is removed by a polishing process. The ends of the side wires 70 are exposed at the back side 901B of the stacked package structure semi-finished product 900B.
Referring to fig. 15 and 16, a redistribution layer (RDL) and a plurality of external terminals 81 are formed on the back surface 901B of the stacked package structure semi-finished product 900B, the redistribution layer is electrically connected to the side wires 70 and the external terminals 81, the redistribution layer includes a dielectric layer 51B and a circuit layer 52B, and the circuit layer 52B is formed of a conductive metal. In one embodiment, the circuit layer 52B may be a multi-layer metal stack, such as Titanium (Titanium, Ti)/Copper (Copper, Cu)/Copper (Cu) or Titanium/Copper/Nickel (Nickel, Ni)/Gold (Au). In one embodiment, the dielectric layer 51B may be a Polyimide (PI) layer for covering and isolating the multi-metal stack of the circuit layer 52B. In one embodiment, the dielectric layer 51B comprises a first dielectric layer and a second dielectric layer formed on and under the circuit layer 52B, respectively. In an embodiment, an Under Bump Metallurgy (UBM) layer is formed between the redistribution layer and the external terminal 81 and electrically connected thereto, and the number of metal layers of the circuit layer 52B and the number of dielectric layers 51 are not limited by the disclosure of the present embodiment and can be designed as required.
Then, a singulation process is performed to form the stacked package structure 90B.
In the embodiment shown in fig. 17, the third encapsulant 80 is covered by a metal layer 82, and the metal layer 82 is grounded or electrically connected to a voltage source to provide emi shielding.
The package-on-package structure 90 according to another embodiment of the present invention may include, but is not limited to, the following structures, and the manufacturing method according to another embodiment of the present invention may include corresponding steps.
After the steps shown in fig. 6 are performed, as shown in fig. 18A and 18B, the second encapsulant 60 is partially removed to form a through hole 61, a scribe line opening 62, and an EMI opening 63C, wherein the EMI opening 63C surrounds the chip package 40.
Referring to fig. 19A and 19B, a side wire 70 is disposed in the through hole 61 and electrically connected to the upper connecting pad 52 and the cutting edge 130, and a conductive wire 83C is disposed in the EMI opening 63C and electrically connected to the ground signal of the substrate 50.
Referring to fig. 20, the chip package 40 and the side wires 70 are covered by the third encapsulant 80C.
Referring to fig. 21, the metal layer 82C is disposed on the third encapsulant 80C and electrically connected to the conductive line 83C. In one embodiment, the conductive line 83C and the metal layer 82C are formed by sputtering.
Referring to fig. 22, a plurality of external terminals 81 are respectively disposed on the lower connection pads 53 of the substrate 50, and then the chip package 40 is singulated along the scribe line openings 62 to form a plurality of stacked packages 90C. In one embodiment, the package-on-package 90C having the conductive line 83C and the metal layer 82C may have at least one redistribution layer and at least one dielectric layer instead of the substrate.
Although the present invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.